Overhead console button carrier having a unitary body

ABSTRACT

An overhead console button carrier has a unitary body. That unitary body includes a first light collimator, a second light collimator, a first intrusion sensor bracket, a second intrusion sensor bracket, a third intrusion sensor bracket and a plurality of button guides. A method and mold assembly for making the overhead console button carrier is also provided.

TECHNICAL FIELD

This document relates generally to the motor vehicle equipment fieldand, more particularly, to a new and improved overhead console buttoncarrier that has a unitary body as well as to a method of making thatoverhead console button carrier and to a mold assembly for that purpose.

BACKGROUND

An overhead console button carrier is a relatively complex componentthat functions to retain push buttons and other components such as righthand and left hand collimators and various intrusion sensors. In thepast it has been necessary to assemble the overhead console buttoncarrier from multiple parts. Such a manufacturing approach has requiredmultiple mold tools, associated fasteners, and assembly labor all addingto the cost of producing an overhead console button carrier.

This document relates to a new and improved overhead console buttoncarrier having a unitary body that includes one or more lightcollimators, one or more intrusion sensor brackets as well as one ormore zero draft button guides. For purposes of this document, theterminology “unitary body” refers to a body originally manufactured inone piece and not requiring assembly from multiple component parts.Advantageously, an overhead console button carrier incorporating aunitary body substantially reduces the complexity and costs ofproduction and, therefore, represents a significant advance in the art.

SUMMARY

In accordance with the purposes and benefits as described herein, a newand improved overhead console button carrier is provided. That overheadconsole button carrier comprises a unitary body including a first lightcollimator, a first intrusion sensor bracket and a first button guide.

The overhead console button carrier may also include a second lightcollimator. The overhead console button carrier may also include asecond intrusion sensor bracket. The overhead console button carrier mayalso include a third intrusion sensor bracket. The overhead consolebutton carrier may also include a plurality of button guides.

The first button guide may have a first centerline axis oriented along afirst direction vector. The first light collimator may have a secondcenterline axis oriented along a second direction vector different fromthe first direction vector. The second light collimator may have a thirdcenterline axis oriented along a third direction vector different fromthe first and second direction vectors.

The first intrusion sensor bracket may have a fourth centerline axisoriented along a fourth direction vector different from the first,second and third direction vectors. The second intrusion sensor bracketmay have a fifth centerline axis oriented along a fifth direction vectordifferent from the first, second, third and fourth direction vectors.The third intrusion sensor bracket may have a sixth centerline axisoriented along a sixth direction vector different from the first,second, third, fourth and fifth direction vectors.

In accordance with an additional aspect, a method is provided for makingan overhead console button carrier having a unitary body. That methodincludes the steps of closing a mold assembly, injecting plastic intothe mold assembly, forming the overhead console button carrier as aunitary body including a first light collimator, a first intrusionsensor bracket and a first button guide, opening the mold assembly andremoving the overhead console button carrier from the mold assembly.

The method may further include the step of forming the unitary body witha second light collimator, a second intrusion sensor bracket and a thirdintrusion sensor bracket before opening the mold assembly. Further, themethod may include the step of using a zero draft core insert to formthe first button guide. Additional zero draft core inserts may beutilized to form additional button guides if desired or needed for anyparticular application.

Still further, the method may include the step of using a first coreside buried retractor mechanism to form the first light collimator.Further, the method may include the step of using a second core sideburied retractor mechanism to form the second light collimator.

In addition, the method may include the step of using a first slidemechanism, carried on a core side of the mold assembly, to form thefirst intrusion sensor bracket. The method may include the step of usinga second slide mechanism, carried on the core side of the mold assembly,to form the second intrusion sensor bracket. The method may include thestep of using a third slide mechanism, carried on the core side of themold assembly, to form the third intrusion sensor bracket.

In accordance with still another aspect, a new and improved moldassembly is provided. That mold assembly may be adapted for producing anoverhead console button carrier having a unitary body. The mold assemblycomprises a cavity side and a core side. The core side includes at leastone zero draft core insert, a first buried retractor mechanism and afirst slide mechanism.

Further, the core side of the mold assembly may further include a secondburied retractor mechanism. The core side of the mold assembly mayfurther include a second slide mechanism. The core side of the moldassembly may include a third slide mechanism.

In the following description, there are shown and described severalpreferred embodiments of the overhead console button carrier, the methodof making an overhead console button carrier and a mold assembly thatmay be utilized to make the overhead console button carrier. As itshould be realized, the overhead console button carrier, the method andthe mold assembly are capable of other, different embodiments and theirseveral details are capable of modification in various, obvious aspectsall without departing from the overhead console button carrier, themethod and the mold as set forth and described in the following claims.Accordingly, the drawings and descriptions should be regarded asillustrative in nature and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

The accompanying drawing figures incorporated herein and forming a partof the specification, illustrate several aspects of the overhead consolebutton carrier, the related method and the mold assembly and togetherwith the description serve to explain certain principles thereof.

FIG. 1 is a perspective view of the overhead console button carrierhaving a unitary body.

FIG. 2 is a top plan view of the overhead console button carrierillustrated in

FIG. 1.

FIG. 3 is a bottom plan view of the overhead console button carrierillustrated in FIGS. 1 and 2.

FIG. 4a is a top plan view of the core side of the mold assembly that isutilized to mold the overhead console button carrier illustrated inFIGS. 1-3.

FIG. 4b is a top plan view of the finished overhead console buttoncarrier resting in the core side of the mold assembly illustrated inFIG. 4a following molding.

FIG. 5 is a top plan view of the cavity side of the mold assemblyutilized to make the overhead console button carrier illustrated inFIGS. 1-3.

Reference will now be made in detail to the present preferredembodiments of the overhead console button carrier, the method of makingthat overhead console button carrier and the mold assembly for makingthat overhead console button carrier, examples of which are illustratedin the accompanying drawing figures.

DETAILED DESCRIPTION

Reference is now made to FIGS. 1-3 illustrating the new and improvedoverhead console button carrier 10. That overhead console button carrier10 includes a unitary body 12. That unitary body 12 is directly moldedin one piece rather than being assembled from a plurality of componentparts. As a result, the overhead console button carrier 10 may beproduced in a simple and inexpensive manner (not previously thoughtpossible) while still allowing for complex functionality.

In the illustrated embodiment, the unitary body 12 includes a firstlight collimator 14, a second light collimator 16, a first intrusionsensor bracket 18, a second intrusion sensor 20, a third intrusionsensor bracket 22 and a first button guide 24. Still further, theunitary body 12 further includes a second button guide 26, a thirdbutton guide 28, a fourth button guide 30, a fifth button guide 32 and asixth button guide 34. Each of the button guides 24, 26, 28, 30, 32, 34includes zero draft to insure the proper operation of any push buttonssubsequently incorporated therein that are adapted for operation ofvarious electrical systems of a motor vehicle into which the overheadconsole button carrier 10 is incorporated.

As illustrated in FIGS. 1-3, the first button guide 24 has a firstcenterline axis C1 that is oriented along a first direction vector. Thesecond, third, fourth, fifth and sixth button guides 26, 28, 30, 32, 34also have their own unique centerline axes oriented parallel to thefirst centerline axis C1. The first light collimator 14 has a secondcenterline axis C2 oriented along a second direction vector differentfrom the first direction vector. The second light collimator 16 has athird centerline axis C3 oriented along a third direction vectordifferent from the first and second direction vectors.

The first intrusion sensor bracket 18 has a fourth centerline axis C4oriented along a fourth direction vector different from the first,second and third direction vectors. The second intrusion sensor bracket20 has a fifth centerline axis C5 oriented along a fifth directionvector different from the first, second, third and fourth directionvectors. Finally, the third intrusion sensor bracket 22 has a sixthcenterline axis C6 oriented along a sixth direction vector differentfrom the first, second, third, fourth and fifth direction vectors.

Reference is now made to FIGS. 4a, 4b and 5 which illustrate the moldassembly 50 utilized to make the overhead console button carrier 10.That mold assembly 50 includes a cavity side 52 and a core side 54. Thecore side 54 includes at least one zero draft core insert 56. Moreparticularly, in the illustrated embodiment, the core side 54 includesthe first zero draft insert 56, a second zero draft core insert 58, athird zero draft core insert 60, a fourth zero draft core insert 62, afifth zero draft core insert 64 and a sixth zero draft core insert 66.

The first zero draft core insert 56 forms the first button guide 24. Thesecond zero draft core insert 58 forms the second button guide 26. Thethird zero draft core insert 60 forms the third button guide 28. Thefourth zero draft core insert 62 forms the fourth button guide 30. Thefifth zero draft core insert 64 forms the fifth button guide 32.Finally, the sixth zero draft core insert 66 forms the sixth buttonguide 34. All of the button guides 24, 26, 28, 30, 32, 34 have their owncenterline axis offset from and parallel to each of the others.

The core side 54 also includes a first buried retractor mechanism 68 anda second buried retractor mechanism 70. Further, the core side 54includes a first slide mechanism 72, a second slide mechanism 74 and athird slide mechanism 76. The first buried retractor mechanism 68 formsthe first light collimator 14. The second buried retractor mechanism 70forms the second light collimator 16. The first slide mechanism 72 formsthe first intrusion sensor bracket 18. The second slide mechanism 74forms the second intrusion sensor bracket 20. The third slide mechanism76 forms the third intrusion sensor bracket 22.

Retractor mechanisms, 68, 70 and slide mechanisms 72, 74, 76 of the typeutilized in the mold assembly 50 described herein are available fromvarious manufacturers/suppliers of mold assemblies including, forexample, Broadway Precision Technology Limited of China with productionfacilities in Shenzhen, China. While such retractor mechanisms 68, 70and slide mechanisms 72, 74, 76 are known to those skilled in the art ofmold design, it is believed that the present mold assembly 50 is thefirst to incorporate retractor mechanisms and slide mechanism with oneor more zero draft core inserts 56, 58, 60, 62, 64, 66. It is the uniqueand novel combination of the actions provided by the retractormechanisms 68, 70 and the slide mechanisms 72, 74, 76 with the zerodraft core inserts 56, 58, 60, 62, 64, 66 that allows the consolidationof the overhead console button carrier 10 into a unitary body 12.

It is the synergistic combination of actions provided by the first andsecond buried retractor mechanisms 68, 70, and the first, second andthird slide mechanisms 72, 74, 76 in combination with the zero draftinserts 56, 58, 60, 62, 64, 66 that allows for the complex structure ofthe overhead console button carrier 10 to be manufactured with a unitarybody 12 that fully functions to orient the button guides 24, 26, 28, 30,32, 34 to receive and allow for proper operation of push buttons, thefirst and second light collimators 14, 16 to receive and allow forproper operation and function of map lights and the first, second andthird intrusion sensor brackets 18, 20, 22 to receive and allow forproper operation and function of intrusion sensors oriented alongspecific direction vectors as required for proper and effectiveoperation.

The method of making the overhead console button carrier 10 comprisesthe steps of: (a) closing the mold assembly 50, (b) injecting plasticinto the mold assembly, (c) forming the overhead console button carrier10 as a unitary body 12 including a first light collimator 14, a firstintrusion sensor bracket 18 and a first button guide 24, (d) opening themold assembly and (e) removing the overhead console button carrier 10from the mold assembly.

The method may further include the step of forming the unitary body 12with a second light collimator 16, a second intrusion sensor bracket 20and a third intrusion sensor bracket 22 before opening the moldassembly. In addition the method may include using a zero draft coreinsert 56 to form the first button guide 24.

A second zero draft core insert 58 may be utilized to form the secondbutton guide 26. A third zero draft core insert 60 may be utilized toform the third button guide 28. A fourth zero draft core insert 62 maybe utilized to form the fourth button guide 30. A fifth zero core draftinsert 64 may be utilized to form the fifth button guide 32. A sixthzero draft core insert 66 may be utilized to form the sixth button guide34. All zero draft core inserts 56, 58, 60, 62, 64, 66 are offset fromand parallel to one another, perpendicular to the mold assembly partline.

The method may include utilizing the first core side buried retractormechanism 68 to form the first light collimator 14. The method mayinclude utilizing the second core side buried retractor mechanism 70 toform the second light collimator.

The method may include using the first slide mechanism 72, carried onthe core side 54 of the mold assembly 50, to form the first intrusionsensor bracket 18. The method may include using the second slidemechanism 74, carried on the core side 54 of the mold assembly 50, toform the second intrusion sensor bracket 20. Further the method mayinclude using the third slide mechanism 76, carried on the core side 54of the mold assembly 50, to form the third intrusion sensor bracket 22.

The foregoing has been presented for purposes of illustration anddescription. It is not intended to be exhaustive or to limit theembodiments to the precise form disclosed. Obvious modifications andvariations are possible in light of the above teachings. All suchmodifications and variations are within the scope of the appended claimswhen interpreted in accordance with the breadth to which they arefairly, legally and equitably entitled.

What is claimed:
 1. An overhead console button carrier, comprising: aunitary body including a first light collimator, a first intrusionsensor bracket and a first button guide.
 2. The overhead console buttoncarrier of claim 1, further including a second light collimator.
 3. Theoverhead console button carrier of claim 2, further including a secondintrusion sensor bracket.
 4. The overhead console button carrier ofclaim 3, further including a third intrusion sensor bracket.
 5. Theoverhead console button carrier of claim 4, wherein said first buttonguide has a first centerline axis oriented along a first directionvector.
 6. The overhead console button carrier of claim 5, wherein saidfirst light collimator has a second centerline axis oriented along asecond direction vector different from said first direction vector. 7.The overhead console button carrier of claim 6, wherein said secondlight collimator has a third centerline axis oriented along a thirddirection vector different from said first and second direction vectors.8. The overhead console button carrier of claim 7, wherein said firstintrusion sensor bracket has a fourth centerline axis oriented along afourth direction vector different from said first, second and thirddirection vectors.
 9. The overhead console button carrier of claim 8,wherein said second intrusion sensor bracket has a fifth centerline axisoriented along a fifth direction vector different from said first,second, third and fourth direction vectors.
 10. The overhead consolebutton carrier of claim 9, wherein said third intrusion sensor brackethas a sixth centerline axis oriented along a sixth direction vectordifferent from said first, second, third, fourth and fifth directionvectors.
 11. A method of making an overhead console button carrier,comprising: closing a mold assembly; injecting plastic into said moldassembly; forming said overhead console button carrier as a unitary bodyincluding a first light collimator, a first intrusion sensor bracket anda first button guide; opening said mold assembly; and removing saidoverhead console button carrier from said mold assembly.
 12. The methodof claim 11, further including forming said unitary body with a secondlight collimator, a second intrusion sensor bracket and a thirdintrusion sensor bracket before opening said mold assembly.
 13. Themethod of claim 12, further including using a zero draft core insert toform said first button guide.
 14. The method of claim 13, furtherincluding using a first core side buried retractor mechanism to formsaid first light collimator.
 15. The method of claim 14, furtherincluding using a second core side buried retractor mechanism to formsaid second light collimator.
 16. The method of claim 15, furtherincluding using a first slide mechanism carried on a core side of saidmold assembly to form said first intrusion sensor bracket.
 17. Themethod of claim 16, further including using a second slide mechanismcarried on said core side of said mold assembly to form said secondintrusion sensor bracket.
 18. A mold assembly, comprising: a cavityside; and a core side including at least one zero draft core insert, afirst buried retractor mechanism and a first slide mechanism.
 19. Themold assembly of claim 18, wherein said core side includes a secondburied retractor mechanism.
 20. The mold assembly of claim 19, whereinsaid core side includes a second slide mechanism.